Box machine

ABSTRACT

A machine for automatically setting up boxes, having a frame which supports a bed and a magazine above the bed for holding box blanks. A pneumatic system draws the blanks one at a time down to the bed, and a plurality of plates sequentially fold the various blank walls and flaps into position.

[ 5] Felb.8,1972

nited States Patent Bowman 33 x 555 ///9 333 999/ u 3 u [54] BOX MACHINE 2,598,569 5/1952 Levkoff... 3,027,815 4/1962 Anness [72] Bwman mdgewmd 3,478,653 11/1969 Byme [73] Assignee: Broach Systems, Inc., Little Ferry, NJ. 3,512,459 5/1970 Di [22] Filed: July 16, 1969 Primary Examiner-Wayne A. Morse, .lr. Attorney-Wolf, Greenfield & Sacks [21] Appl.No.:

ABSTRACT [52] US. Cl..........................93/49 R, 93/51 HW, 93/53 AC,

A machine for automatically setting up boxes, having a frame [51] Int. Cl. which supports a bed and a magazine above the bed for hold [58] Field of Search..................93/49, 49 M, 51 HW, 53 AC, ing box blanks. A pneumatic system draws the blanks one at a time down to the bed, and a plurality of plates sequentially fold the various blank walls and flaps into position.

3 Claims, 17 Drawing Figures Re 23,669 Berch.....................................93/49 X PATENTEU EB 8 I972 sum mar :11

INVENTOR. PAUL F. BOWMAN ATTORNEYS PATENTED FEB 8 1972 saw our 11 F IG. 7

FIG. 9

INVENTOR. PAUL F BOWMAN 7? 4 ',%M/ M ATTORNEYS PATENTEUFEB m 7 SMET 85% H INVENTOR- PA UL BOWMAN ATTO EYS sis-40.189

PATENTED FEB 8 I972 QM? @EUF 11 INVENTOR. PA U L F B OWM AN ATTORNEYS MWWMB wz 3,640,189

SHEET 070$ 11 NVENTOR.

PAUL F. BOWMAN ATTORNEYS PATENTEU res 84972 3.640.189

SHEH 08W 1? minim ATTQRNEYS PATENTED FEB 8 I972 SHEET USUF 11 INVENTOR. PAUL F. BOWMAN M 4244, WM M ATTORNEYS PATENTED FEB 8 m2 SHEET 10 W H INVENTOR. PAUL F. BOWMAN BY flag/3 ATTORNEY-3 PATENTED FEB 8 H72 SHEET 11 HF H INVENTOR. PAUL F. BOWMAN BY I 4 a ATTORNEYS BOX MACHINE This invention relates to the setting up of boxes, and more particularly comprises a machine for automatically setting up boxes one at a time from blanks stored in a magazine on the machine.

The object of this invention is to provide a machine capable of receiving a stack of box blanks and assembling them one at a time without the assistance or attention of an operator.

To accomplish this and other objects, this invention includes among its features a frame which supports a box-folding bed and a storage magazine. Feeding means are incorporated into the machine which automatically draw blanks from the magazine one at a time and deposit them on the bed. The bed is composed of a number of plates which sequentially operate to fold the blank walls and flaps into position so that the box is in a set up condition to receive goods.

In the drawings:

FIG. 1 is a perspective view of a machine for setting up'box blanks, in accordance with this invention;

. FIG. 2 is a perspective view looking up at the magazine on the top of the machine shown in FIG. 1;

FIGS. 3-7 are perspective views showing the various operations carried out in sequence by the machine to set up the box blank;

FIG. 8 is a perspective view of the machine as it reverses the steps to free the box;

FIG. 9 is a perspective view of the setup box;

FIG.10 is a plan view of the box blank which is set up on the machine;

FIG. 11 is a rear elevation view of the machine with the various plates in the position of FIG. 6 to set up the front, rear, and sidewalls of the box;

FIG. 12 is a top plan view of the machine shown in the condition of FIG. 11;

6 FIG. 13 is a plan view of the bed of the machine open as in FIG. 1 in a condition to receive the box blank;

FIG. 14 is a side view of the machine with the bed folded as in FIGS. 6, 11 and 12;

FIG. 15 is a front elevation view of the machine with the front and side plates of the machine as in FIG. 3;

FIG. 16 is a front elevation view of the machine with the bed horizontal as in FIG. 1; and

FIG. 17 is a side view of the bed in the condition of FIGS. 1, 13 and 16.

Before describing the machine of this invention which sets up the box, the blank shown in FIG. 10 from which the box shown in FIG. 9 is made will be described.

In FIG. 10 the box blank 20 is shown made up of a number of panels which define the six walls of the box as well as the locking flaps and their tongues and slots. The box bottom 22 is separated from the front wall 24 and the backwall 26 by fold lines 28 and 30. End walls 32 and 34 lying on opposite sides of the front wall 24 are separated from the front wall by fold lines 36 and 38. Disposed beyond the ends of the bottom panel 22 are bottom flaps 40 and 42 which are attached to the end walls 32 and 34 respectively by fold lines 44 and 46. The inside edges 48 and 50 of each bottom flap 40 and 42 are severed from the bottom panel 22 so that the bottom flaps '40 and 42 may be folded up out of the plane of the paper in FIG. 10 along the fold lines 44 and 46 respectively. A pair of end flaps 52 and 54 are secured to the ends of the back panel 26 by fold lines 56 and 58 respectively, and the other edges of the end flaps 52 and 54 are severed from the remaining portions of the box blank. A pair of locking flaps 60 and 62 are joined to the side edges of the end wall 32 and 34 respectively by double fold lines 64, 66 and 68, 70. The inside edges 69 and 71 of locking flaps 60 and 62 are cut from the ends of the top panel 72, and the flaps carry tongues 74 and 76 that fit into the slots 78 and 80 respectively formed in the edges of the bottom flaps 40 and 42 when the box is set up. Tongue 82 carried by the side edge 84 of the top panel 72 is designed to lock in the slot 84 formed in the top flap 86 joined to the back panel 26 along fold line 88.

The sequence in which the various folds are made in the blank 20 as the box is set up are called out by letters A to F, and the steps are described briefly as follows: First, the bottom flaps 40 and 42 are bent up slightly from fold lines 44 and 46 (step A) so that the ends 90 and 92 lie above the plane of the bottom panel 22. Next, the blank is folded along line 28 (step B) so that the front panel 24 and the end panels 32 and 34 as well as locking flaps 60 and 62, and top panel 72 he in a vertical plane. Next (step C), the blank is folded along the vertical fold lines 36 and 38 to bring the end walls 32 and 34 into position adjacent the ends of the bottom wall. When the end walls 32 and 34 are folded as suggested, the locking flaps 60 and 62 also pivot with them along the vertical axes defined-by the fold line 36 and 38 and form vertical extensions of the end walls. Folding the end walls 32 and 34in the manner described also moves the bottom flaps 40 and 42 into position above the ends of the bottom panel 22. That is, the flaps 40 and 42 overlie the bottom wall and the fold lines 44 and 46 coincide with the end edges of the bottom wall. As step D, the end flaps 52 and 54 are folded upwardly along the fold lines 56 and 58 so that their outer edges 94 and 96 respectively lie inside the planes of the end walls 32 and 34. Next, the backwall 26 is folded along the line 30 (step E) so that the back 26 lies in a vertical plane parallel to the front 24. When the back 26 is folded in this manner, the end flaps 52 and 54 move inside the end walls 32 and 34 and lie against their inner surfaces. As step F, locking flaps 60 and 62 are folded downwardly along their fold lines 64, 66 and 68, 70 into the box so that they lie against the inside of end flaps 52 and 54. The tongues 74 and 76 lock into the slots 78 and to hold the locking flaps 60 and 62 in place. The narrow strips 65 and 67 between the pairs of fold lines 64, 66 and 78, 70 straddle the tops of the end flaps when the box is assembled When these steps are completed the box is set up as shown in FIG. 9.

When the box is to be closed, the top flap 86 is foldedalong its line'88 (step G) to a horizontal plane and theend flaps 87 are folded in against the locking flaps 60 and 62,'and the top wall 72 is folded along its fold line 98 (step H). The tongue 82 is folded along the line 84 (step I). Consequently, as the top wall 72 moves into the horizontal position, the tongue 82 enters the slot to retain the box in the closed form.

With the foregoing description, the operation of the machine which sets up the box will be more readily understood.

The machine includes a frame 100 with a platform 102 supported on four legs 104 that extend upwardly through the platform and also support the top wall 106. The wall 106 carries a magazine 108 which contains the stack of blanks 20 to be set up by the machine. The top wall 106 is shownin FIG. 2 to define a horizontal frame which'allows the blanks to be drawn one at a time out of the bottom of the magazine 108 and onto the bed 1 10 described by various plates that comprise the working parts of the machine and which are supported on the platform 102 beneath the top wall 106.

The bed 110 includes a center plate 112 fixed in position above the platform 102 and which supports the bottom panel 72 of the blank when it is drawn from the magazine 108. The plate 112 has a pair of circular openings 114 provided in its surfacewhi'ch receive a pair of suction cups 1 16 shown in FIG. 2 that engage the lowermost blank 20 in the magazine 108 and draw it downwardly to the bed. The suction cups 116 are mounted on the top of axially movable pipes 118 carried by block 120 supported on the upperend of piston rod 122 forming part of air cylinder 124 disposed beneath the platform 102. The pipes 118 are connected by means of hoses (not shown) to a vacuum pump (not shown) to apply a suction to the cups 116 so that they may in turn engage and draw downwardly from the magazine 108 the lowermost blank in it.

Disposed about the four sides of the plate 112 are a number of different folding plates which engage the blank and perform the various folding functions described above to set up the box. When the blank is drawn from the magazine down to the bed 110, the bottom panel 22 rests on the plate 112 which conforms in size and shape to panel 22, and the suction cups 116 lie in the plane of the plate 112 as suggested in FIG. 11. The block 120 carried by the piston rod 122 moves through an opening formed in the plate, in part defined by the openings 114 so that the block lies below it as seen in FIG. 11.

In FIGS. 1, 3, and 17 a pair of pins 126 are shown which extend upwardly through the plates 160, and the pins 126 serve to fold the bottom flaps 40 and 42 upwardly slightly from the plane of the bottom panel 22 (step A) as suggested in FIG. 3.

The pins 126 serve automatically to fold the bottom flaps 40 and 42 upwardly out of the vertical plane along the fold lines 44 and 46 merely by their presence. That is, as the blank is drawn downwardly by the suction cups and is supported in a horizontal plane on the bed 110, the pins 126 engage the undersides of the bottom flaps 40 and 42 adjacent their edges 90 and 92 and prevent them from reaching the horizontal plane of the surface of the bottom plate 112 of the bed.

The front wall 24 of the blank is raised (step B) to the position shown in FIG. 3 by the front plate 130 which is pivotally supported along its edge 132 by pins 134 (see FIGS. 13, 15 and 17) on frame members 135 so that it may be raised to the vertical position from its normal horizontal position. The plate 130 is elevated by a cylinder 136 mounted on platform 102 and whose piston rod 138 is pivotally secured to the underside of the plate 130 by bracket 139. The plate 130 is substantially the same size as the front panel 24 of the box blank, and, therefore, when it is pivoted about the pins 134 by the cylinder 136, it folds the front wall 24 along the fold line 28 to the vertical position shown in FIG. 3. Simultaneously, the end walls 32 and 34 of the blank are also folded to the vertical plane. This is achieved by the end plates 140 which are carried by the front plate 130 (see FIG. 13). The end plates 140 are pivotally secured to the edges 142 of the front plate 130 by pins 144. Because the end plates 140 are carried by the front plate 130, they pivot to the vertical plane with the front plate when it is actuated by the cylinder 136. It is evident in FIG. 3 that when the plate 130 assumes the vertical position, the end plates 140 similarly assume the vertical position so as to fold the end walls 32 and 34 of the blank to the vertical plane coincident with the plane occupied by the front panel 24. It will also be noted in FIG. 3 that the top wall 72 and the locking flaps 60 and 62 assume the same vertical plane under the influence of the front plate 130 and the end plates 140 of the machine.

The next fold (step C) is made when the machine moves as shown in FIG. 4. In FIG. 4, the end plates 140 are shown pivoted about their pins 144 on the side edges of plate 130 so as to move the end walls 32 and 34 of the blank along with the locking flaps 60 and 62 into a vertical plane perpendicular to the bottom wall 22 and the front wall 24 of the box. This is also shown in FIG. 5, wherein an additional step is shown, namely, the end flaps 52 and 54 are elevated to the vertical position.

It will be noted in FIG. that with the end walls 32 and 34 folded into position about their fold lines 36 and 38, the bottom flaps 40 and 42 are moved so as to overlie the ends of the bottom wall 22 of the box. The end plates 140 which fold the end walls 32 and 34 to their assembled position are actuated by the parallel cylinders 146 and 148 which are oppositely directed as shown in FIG. 15. Thus, the cylinder 146 is anchored at its right end to the edge of plate 130, while its piston rod 150 is secured by bracket 152 to the left end plate 140. Conversely, the left end of cylinder 148 is shown secured to the left side of plate 130 in FIG. 15, while its piston rod 154 is secured by bracket 156 to the right end plate 140. Therefore, when the cylinders 146 and 148 are actuated to extend their piston rods 150 and 154, the end plates 140 pivot on their pins 144 as shown in FIG. from the plane of the paper in a downward direction. The position of the end plates 140 when pivoted is clearly shown in FIG. 14 with the cylinders 146 and 148 extended to perform the actuating functions.

As suggested above, FIG. 5 illustrates the next operation (steps D) wherein the end flaps 52 and 54 are elevated. The end flap walls 160 of the machine are generally pie shaped with an outer arcuate edge 162 and each is supported by pins 164 for pivotal movement about a horizontal axis on the upper ends 167 of posts 169 forming part of the frame. As is shown clearly in FIG. 13, pins 126 extend upward through slots 171 provided in the sides 170 of the end flap plates 160 so that the plates 160 may pivot to the vertical plane as in FIG. 5 without interference from the pins. In FIGS. 5 and 14, the manner in which the end flap plates 160 are actuated is shown. It will be noted in those FIGURES that a cylinder 172 is supported at its lower end on platform 102, and its piston rod 174 is connected by bracket 176 to the lower surface of the plate 160. Thus when the cylinder 172 is energized to extend its piston rod 174, the plate 160 in each instance is pivoted about its pins 164 to raise the end flaps 52 and 54. (While FIG. 14 shows but one of the end flap plates, it is to be understood that both are the same).

The next step (step E) in setting up the box blank is suggested in FIG. 6, wherein the backplate 168 is shown in its vertical position. The plate 168 in FIGS. 13 and 17 is shown supported on pins 180 also secured to the frame of the bed so that it may be moved to a vertical plane to elevate the backwall 26 of the blank to carry out step E in the setting up of the box. When the blank backwall 26 is elevated, the end flaps 52 and 54 connected to the backwall, which have previously been raised to a vertical plane (see FIG. 5) roll edgewise inwardly to a position in front of the end walls 32 and 34 and above the bottom flaps 40 and 42. That is, the end flaps 52 and 54 lie in planes parallel to the end walls 32 and 34 and perpendicular to and overlying the outer, secured edges of the bottom flaps 40 and 42.

The backplate 168 is actuated by a cylinder 182 supported on platform 102 and whose piston rod 184 is secured to the lower surface of the plate 168 by bracket 186 as shown in FIGS. 6 and 11. When the backplate 168 is elevated, it moves upwardly between the end flap plates which lie on each side of it.

When the box is set up through step E, the bottom, front, and backwalls 22, 24 and 26 respectively are each in their assembled position, as are the end walls 32 and 34, the bottom flaps 40 and 42, and the end flaps 52 and 54. However, the locking flaps 60 and 62 are not in their assembled position, but rather they extend vertically and upwardly from the double folds at the top of walls 32 and 34, and the top wall 72 and top flap 86 are also disposed vertically, extending upwardly from the top edges 98 and 88 respectively of the front and backwalls. The box is locked in its assembled position by means of the locking flaps 60 and 62 which are actuated by the paddle assemblies 190.

The paddle assemblies 190 are mounted on the end plates 140 (see FIGS. 7, 8, 14 and 15). In each assembly a bracket 192 on the top of each sideplate 140 supports a shaft 194 between two of its plates 196 and 198 which shaft pivotally carries the T-shaped inner end 200 of the paddle plate or locking flap plate 202. A pinion 204 is also secured to the shaft 194 between the bracket plate 198 and the third bracket plate 206, and a rack 208 mounted on the end of piston rod 210 engages the pinion 204 to rotate it and cause the paddle plate 202 to pivot and fold the locking flap over into the box in the down position. The piston rod 210 forms part of the cylinder 212 fully supported by brackets 214 on the end plate 140, and therefore the cylinder, its associated parts, and the paddle assembly 190 all move with the end plate 140 when it in turn is pivoted on the edge of the front plate 130. In FIG. 7 the manner in which the rack 208 actuates the locking flap plate 202 is plainly illustrated. When the piston rod 210 moves to its extended position, it rotates the pinion 204 which causes the paddle plate 202 to move from the raised position shown in FIG. 15, approximately to the lower position so that the paddle plate lies within the box as in FIG. 7. FIG. 11 also clearly illustrates this arrangement. The rack 208 is shown held against the pinion 204 by the pressure rollers 216.

Each of the paddle plates 202 includes not only the T- shaped inner end 200, but a rectangular extension 218 carried on pins 220, and spring biased by coil springs 222 to extended position away from the end 200. The rectangular extension 218 can be moved toward the T-shaped end 200 against the bias of the springs 222, which allows the paddle plate 202 to extend fully to the bottom of the box when it is turned downwardly as shown in FIG. 7 to cause the tongues 74 and 76 of the locking flaps to lock in the slots 78 and 80 at the inner edge of the bottom flaps 40 and 42. Thus, the paddle plates 202 may slide along the bottom of the setup box as they move to the position shown in FIG. 7 and generally prevent the tongues 74 and 76 from bending on' the locking flaps before they reach the slots 78 and 80.

In the foregoing description the various parts of the machine have been described and their operation will be reviewed below with reference to the several FIGURES to assist in a full comprehension of the machine.

In FIG. 1, 16 and 17 the bed 110 is shown in its initial condition with all of the several plates being arranged horizontally. Thus, when the suction cups 116 draw down a blank 70 from the magazine 108, the blank is allowed to lie flat on the bed 110 except for the bottom flaps 40 and 42 which are tilted upwardly by the pins 126 (step A).

In FIGS. 3 and 15, the front plate 130 is shown raised along with the end plates 140 to perform step B, and pins 126 have raised the bottom flaps 40 to perform step A.

In FIG. 4 the machine is shown in the position it assumes to perform step C, namely the folding of the end walls 32 and 34 into position by the movement of the end plates 140 about the pivotal supports 144.

In FIG. 5 the end flap plates 160 are shown in their elevated position to perform step D.

In FIGS. 6, ll, 12 and 14 the various plates are shown in the position they assume when step E is performed, namely, the backwall 26 is folded upwardly and the end flaps 52 and 54 are moved into position on the insides of the end walls 32 and 341.

In FIG. 7 the machine is shown in the position to perform step F, namely, folding down locking flaps 60 and 62 on the double fold lines 64, 66 and 68, 70 so that the narrow walls 65 and 67 bridge the tops of the end walls 32 and 34 and end flaps 52 and 541. Note in FIG. 7 that the paddle plates 202 are in their downwardly extended position disposed within the box to push the tongues 74 and 76 into the locking slots 78 and 80.

After the box is assembled in the manner described, the various steps in the operation of the machine are reversed so as to free the box from the plates and condition the machine so that it may receive the next blank. In FIG. 8 the beginning of this reversed operation is suggested, as the paddle assemblies 190 are shown in their elevated position and the box is fully formed. The box when formed as described assumes the condition of FIG. 9. After the box is filled, the top flap 86 may be folded down with its ears 87 inside the end flaps 52 and 54, and thereafter the top wall 72 may be folded down and its tongue 82 inserted into slot 85.

While no specific means is shown in the drawings, it will be appreciated that some automatic means may be provided to remove each box from the bed 110 after it is formed and before the next blank is drawn down upon the open bed. However, that mechanism forms no part of this invention. It will also be appreciated that the various cylinders which actuate the plates will in normal use be programmed so as to function in sequence both while folding the box and opening so as to allow the box to be removed. The cylinders shown are pneu matic, and it will be appreciated that an array of valves may be provided operated sequentially to actuate the various cylinders.

In the drawings it will be noted that bottom plate 112, front plate and backplate 168 are each split. While this arrangement may be used, unbroken plates may be used with equal facility.

What is claimed is:

l. A machine for automatically setting up boxes from box blanks, said boxes including three-ply end walls and a reinforced bottom wall, comprising, a frame,

a bed for setting up boxes and a magazine for carrying box blanks supported above and centered with respect to the frame,

a fixed center plate being horizontally oriented forming part of the bed and conforming in size to the bottom wall of the box and having front, rear and side edges,

feeding means including at least one suction device movable through the fixed center plate for drawing the blanks one at a time from the magazine down to the bed,

a plurality of additional plates being normally positioned in horizontal planes forming part of the bed and pivotally mounted on the frame along the front and rear edges of the fixed plate for folding the front and rear walls of the blank to their assembled position, said bed being free of plates pivotally mounted along the side edges of the fixed plate,

pneumatic means connected to each of the additional plates to move them about'their pivotal supports to planes perpendicular to the fixed center plate, with said pneumatic means acting to move one of said additional plates out of its horizontal plane in one step and acting to move another of said additional plates out of its horizontal plane in a subsequent step,

further pairs of plates pivoted along the sides of the additional plates for folding two plys of the end walls of the blank to their assembled position,

paddle assemblies pivotally mounted on said further pairs of plates and extending upwardly therefrom when the pairs of plates are in a vertical plane,

and means connected to the assemblies for turning them through approximately downwardly into the assembled box to fold the locking flaps into the box.

2. A machine as described in claim 1 further characterized said paddle assemblies each including a paddle plate comprised of top and bottom parts movable with respect to one another,

and means yieldably biasing the parts to a maximum separated condition wherein the plates have a maximum size.

3. A machine as described in claim 1 further characterized pins extending up from the plane of the bed for elevating selected flaps in the blank when it is drawn down onto the bed. 

1. A machine for automatically setting up boxes from box blanks, said boxes including three-ply end walls and a reinforced bottom wall, comprising, a frame, a bed for setting up boxes and a magazine for carrying box blanks supported above and centered with respect to the frame, a fixed center plate being horizontally oriented forming part of the bed and conforming in size to the bottom wall of the box and having front, rear and side edges, feeding means including at least one suction device movable through the fixed center plate for drawing the blanks one at a time from the magazine down to the bed, a plurality of additional plates being normally positioned in horizontal planes forming part of the bed and pivotally mounted on the frame along the front and rear edges of the fixed plate for folding the front and rear walls of the blank to their assembled position, said bed being free of plates pivotally mounted along the side edges of the fixed plate, pneumatic means connected to each of the additional plates to move them about their pivotal supports to planes perpendicular to the fixed center plate, with said pneumatic means acting to move one of said additional plates out of its horizontal plane in one step and acting to move another of said additional plates out of its horizontal plane in a subsequent step, further pairs of plates pivoted along the sides of the additional plates for folding two plys of the end walls of the blank to their assembled position, paddle assemblies pivotally mounted on said further pairs of plates and extending upwardly therefrom when the pairs of plates are in a vertical plane, and means connected to the assemblies for turning them through approximately 180* downwardly into the assembled box to fold the locking flaps into the box.
 2. A machine as described in claim 1 further characterized by said paddle assemblies each including a paddle plate comprised of top and bottom parts movable with respect to one another, and means yieldably biasing the parts to a maximum Separated condition wherein the plates have a maximum size.
 3. A machine as described in claim 1 further characterized by pins extending up from the plane of the bed for elevating selected flaps in the blank when it is drawn down onto the bed. 